High Performance Trays Enhanced Deck and Downcomer Technology

Sulzer Chemtech

Sulzer "Plus" Technology

Sulzer VG AFTM

Shell HiFiTM Trays

6

9

10

Shell ConSepTM Trays 12

Mechanical Features and Services 14

Tray Portfolio Sulzer Technology Sulzer-Shell Alliance

Floating Valves

BDHTM / BDPTM

Round Valves

Fixed Valves

SVGTM / LVGTM

SVG-HTM

Other Trays

Bubble Cap

Sieve

Dual Flow

Baffle

Disc and Donut

Shower Deck

Cartridge

Slit TraysTM

Enhanced Deck

MVGTM

MMVGTM

UFMTM

Enhanced Deck and Downcomer

VGPlusTM

UFMPlusTM

Multi Downcomer High Performance Trays

Shell HiFiTM

Shell HiFiTM Plus

Shell Calming SectionTM (CS)

Shell CSTM Plus

Dual Flow High Performance Trays

Shell CS GridTM

e-VGPlusTM

Ultra-System Limit High Performance Trays

Shell ConSepTM

High Performance TraysWe understand the ever increasing requirement for both reliability and performance of your process equipment. To meet these challenges, you can rely on our innovative, industry-leading products and expertise. Our extensive tray portfolio ranges from single pass to multi-downcomer as well as conventional to high-performance, including the latest technology in ultra-system limit trays. All designs are tailored to meet the exact requirements of your specific application.

For your most demanding applications, our High Performance Trays include VGPlusTM trays with

MVGTM decks and enhanced downcomer technology as well as the newest trays, UFMPlusTM with UFMTM valves. The UFM valve is an industrially proven, advanced movable mini-valve providing the highest efficiency and capacity. For fouling applications that require high performance, our VG AFTM Anti-Fouling trays provide a proven and robust solution. This portfolio has been greatly enriched since 2000 by our technology alliance with Shell Global Solutions, and also includes Shell high performance trays such as the Shell HiFiTM trays, ideal for high liquid load applications, and Shell ConSepTM trays with proven ultra-system capabilities.

High Performance Trays featured in this brochure

XVGTM

Sulzer Chemtech- Mass Transfer TechnologyYour Partner in Separation and Mixing Technology

A Broad Range of Innovative and High-performing ProductsOur more than 200 products cover a wide range of needs in the field of separation and mixing technology. They have proven their performance in more than 100,000 columns, 40,000 gas/liquid separators and 100,000 mixers in operation worldwide.

Naphtha

Kero

Diesel

Comprehensive Engineering and Technology ServicesWe provide a full scope of associated engineering and technology services to optimize or trouble-shoot your installation.

Fast and Reliable Turnaround ServicesYou can rely on Sulzer professionals, expertise and procedures to get you back and running in the shortest possible time.

The Highest Level of Application Know-howOur team provides state-of-the art expert know-how for more than 500 applications in 100 processes, this enables us to optimize the performance and your installation.

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e-UFMPlusTM

VG AFTM

Conventional Trays Chordal Downcomer High Performance Trays

54

Leading Tray Technology

1900 2000 2010

In the 1820s, an early version of bubblecaps trays were introduced for continous distillation towers.

In the 1950s, valve trays were developed, providing higher capacity and better efficiency over a wider operating range.

The modern valve tray, a rectangular float valve tray, was first installed by I.E. Nutter in 1951. By 1956, different variations of round valves had surfaced.

In the 1830s, sieve trays were developed, offering higher capacity despite design simplicity.

In 1998, Sulzer acquired Nutter Engineering, incorporating the well-acclaimed BDHTM rectangular float valve and V-Grid fixed valves into Sulzer's tray product portfolio.

Bubblecaps in Sulzer's Tray Portfolio Round Valve Caged Valve

Modern 1-pass Sieve Tray

BDHTM Rectangular Float Valve

VGrid Fixed ValvesFrom Left to Right: SVGTM, MVGTM and MMVGTM Fixed Valves

In 2000, Sulzer formed a technology alliance with Shell Global Solutions providing a full range tray product portfolio from one source. These include Shell Calming SectionTM (Plus) Trays, Shell HiFi (Plus) Trays and ultra-high capacity Shell ConSep Trays.

In 2012, Sulzer launched a new valve product – UFM (Umbrella Floating Mini), a movable valve which provides higher capacity and a wider operating range than conventional valves.

In 2014, Sulzer launched UFMPlus, a high performance tray with a UFM deck and enhanced downcomers.

Shell HiFiTM Tray Shell ConSepTM Tray

In 2000, Sulzer introduced high performance VGPlus

trays which provide higher capacity with the combination of enhanced downcomers and optimized tray layout.

Sulzer’s 6-pass VGPlus High Performance Trays were successfully installed in several C3 Splitters and are performing beyond expectations.

6-pass trays are a natural progression after 4-pass trays for large diameter columns (typically > 6 m) with high liquid loads.

Sulzer has also introduced high performance VG AF Anti Fouling Trays featuring large fixed and push valves, and fouling resistant outlet weirs.

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Key Areas of Application

Sulzer "Plus" Technology

VGPlus and UFMPlus Trays, are Sulzer’s high performance “Plus” technology chordal downcomer trays. They offer industry proven and validated advanced tray technology for today’s market.

Enhanced DowncomersA main feature of Sulzer "Plus" technology trays is the use of high performance downcomers such as highly sloped, Truncated, StepArc (stepped) and ModArc (multi-chordal) downcomers. These downcomer designs maximize the tray deck area by optimizing the downcomer bottom area, thereby increasing vapor handling capacity and reducing pressure drop and backup.

Enhanced Decks Sulzer "Plus" technology trays can be equipped with high capacity fixed valves or float valves. VGPlus trays are equipped with high capacity fixed valves such as MVG or MMVGTM while UFMPlus trays use high capacity UFM float valves.

Redirecting and froth promoting devices such as push valves and baffle bars, enhance the vapor/ liquid interaction on the tray deck.

4-pass VGPlusTM tray equipped with ModArc downcomers, MVGTM and push valves

VGPlusTM Trays VGPlus Trays are enhanced downcomer trays with high capacity MVG or MMVG fixed valves.

MVG valves provide higher capacity compared to standard sieve or conventional valves, while providing higher efficiency and lower pressure drop per theoretical stage. The MVG tray deck offers better turndown capability than a sieve tray, i.e. up to 3:1.

MMVG valves are used where extremely high vapor capacity or a very low pressure drop is required. The smaller size opening compared to MVG results in up to 7% additional capacity.

UFMPlusTM Trays UFMPlus Trays are enhanced downcomer trays with high capacity UFM float valves.

UFM valves are an advanced type of movable mini-valve which maximize the hydraulic capacity, the separation efficiency, and the operating range of fractionation trays.

The "Umbrella" shape of UFM valves reduces the jetting momentum of the released vapor which maximizes the contact area of vapor and liquid on the tray deck and promotes uniform mixing and minimizes entrainment.

The UFM tray deck offers better turndown capability than a fixed valve tray, i.e. up to 5:1.

FRI Validation

Sulzer VGPlus Trays have been tested at FRI, in the iso-butane/n-butane system at 7 and 11 bar. The VGPlus tray is one of the best performing trays ever tested, delivering up to 10% higher capacity than some other tested competitor's high performance trays.

• Refinery: Main Fractionators and Gas Plants• Olefins: Deethanizers,Depropanizers, Debutanizers, Deisobutanizers, SuperFractionators: C2 and C3 Splitters • Aromatics: Xylene Splitters, Xylene Rerun, Raffinate Columns

Truncated downcomer StepArcTM downcomer ModArcTM downcomer

e-VGPlus and e-UFMPlusSulzer also offers e-VGPlus and e-UFMPlus, our new e-series enhanced high performance trays. These trays are equipped with capacity enhancement features, which further optimize the utilization of the tray decks, for maximum potential capacity of chordal downcomer trays. Depending on process conditions and tray designs, these enhancement features can offer up to 12% higher capacity than our Sulzer “Plus” Technology trays - VGPlus and UFMPlus. Kindly contact Sulzer Chemtech for a technical evaluation.

Liquid Flow Study with Conventional Trays

"Plus" technology with baffle bars

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Case Study - Revamp of Deisobutanizer with VGPlusTM Trays

A refinery deisobutanizer column, upstream of an HF Alkylation Unit, was identified to be the bottleneck of the capacity expansion. This deisobutanizer column of ID 2.96m was originally equipped with 56 2-pass conventional round valve trays. A process study highlighted that the throughput could be almost doubled by retrofitting the tower with high performance trays.Revamp Objective: • Maximize the production of iC4 • Minimize nC4 in top product: <3 wt% • Maximize iC4 recovery: >94 wt%Revamp Solution: Sulzer VGPlus High Performance Trays with • MVG Fixed Valves • ModArc Side Downcomers • Froth Enhancers: Push Valves Test run was performed at 143% of the pre-revamp capacity due to shortage of feedstock. To further load the tower, the reflux ratio was increased till maximum reboiler duty: the production of iC4 increased by 57%, with a nC4 impurity as low as 0.9 wt% and iC4 recovery over 98 wt% leading to a tray efficiency over 93% even at flooding close to 90%.

Sulzer's Experience - 6-Pass VGPlusTM Trays for new C3 Splitters

Three new C3 Splitters, each designed with 195 6-pass VGPlus High Performance Trays.For columns with large diameters, 6-pass trays provide extensive weir length to handle the high liquid loads. The multiple pass design also avoids excessively long flow path lengths to mitigate undesirable liquid flow gradients on the tray decks. Enhanced downcomers are utilized to maximize the bubbling area for mass transfer. Sulzer Design: Sulzer VGPlus High Performance Trays with • MVG Fixed Valves • ModArc Side Downcomers • Froth Enhancers: Push Valves

Before Revamp

Design Test Run

Feed flow rate 100% 191% 143%

Top iC4 flow rate 100% 193% 157%

Reflux ratio NA 12.7 17.5

Tray efficiency NA 86% > 93%

nC4 impurity > 3 wt% 3 wt% < 0.9 wt%

iC4 recovery < 94 wt% 94 wt% > 98 wt%

Flooding NA 80% 89%

VG AFTM AntiFouling Trays

VG AFTM Trays VG AF (AntiFouling) trays are part of the VGPlus tray family and especially designed for fouling services.Features of VG AF which increase tray fouling resistance and run length:• Large V-Grid: SVGTM or XVGTM • Modified outlet weirs: stepped or sloped weirs • Push valvesThe VG AF provides superior anti-fouling performance while delivering high capacity and efficiency, making this tray ideal for debottlenecking fouling services.

Key Areas of Application

• Primary Fractionators in Ethylene Plant• Stripping Section of CDU and VDU • Coker Main Fractionators • Heads and Dry Columns of Acrylonitrile Plant• PVC Slurry Strippers• Beer Columns

2-pass VG AFTM with V-Grid, sloped outlet weir and push valves

Sulzer "Plus" Technology

56

1

28

n-C4

29

Feed-1

Feed-2

Feed-3

From Iso-Stripper

Reboiling Fluid

FC

FC

LC

FC LC

LC FC

10 FC

TC

Fuel Gas

Iso-C4

PC

New VGPlus HPTrays

2-pass VG AFTM trays equipped with V-Grid, stepped outlet weir and push valves

Case Study - Revamp of Acrylonitrile Heads and Dry Column to VG AFTM

Acrylonitrile (ACN) Heads and Dry Column was revamped from round valves trays to Sulzer VG AF AntiFouling trays for higher performance and longer run length. This ACN Column was originally equipped with 62 1-pass conventional round valve trays. Revamp Objective: • Increase capacity by 25% • Maximize Acrylonitrile recovery: > 91 wt% • Maximize run length: > 6 months Revamp Solution: Sulzer VG AF Antifouling Trays with • SVG Fixed Valves • Stepped Outlet Weirs • Froth Enhancers: Push Valves As a result of the revamp with VG AF trays, the column capacity increased by 25%. The ACN recovery improved to 95% and the run length increased to more than 11 months.

Before Revamp

After Revamp

Feed 100% 125%

ACN Production 100% 130%

ACN Recovery 91 wt% 95 wt%

Tray Efficiency 70% 74%

Run Length [months] 4 >11

From Dec. Recovery Column

CW

BRINE

Quench Tower

HCN Tower

Product Tower

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Shell High Performance Trays

Sulzer's Experience - New Shell HiFiTM Trays for Crude Distillation

Revamp of top 3 rectifying trays of a Crude Distillation Column from conventional trays to Shell HiFi trays which offer longer weir length to handle the higher liquid loads. Due to large column diameter of 9.6m, two beams were required for each tray.

Revamp Design: Shell HiFi Trays with 2 beams design • 21 HiFi Downcomer Boxes • Long Weir Length > 110m

Shell HiFiTM Plus TraysShell HiFi trays are fractionation trays equipped with multiple envelope downcomers, oriented offset to the tray's center line.

They are supported on a 360° support ring and central major beams, without the need of the downcomer bolting bars.

For a given column diameter, they allow for:

• Highest number of passes • Large downcomer area • Long weir length • High hydraulic capacity • Low tray spacing • High NTS per column height

The HiFi Plus trays are an enhanced version featuring advanced valves (i.e. MVG, MMVG, UFM) to further boost the tray deck performance, and/or the Crown Inlet Device CIDTM to maximize the downcomer capacity as well.

HiFiTM Plus tray with MVGTM valves

Case Study - Revamp of C2 Splitter to Shell HiFiTM Plus Trays

A C2 Splitter (3.96m I.D.), was revamped from 153 competitor's Multi-Downcomer trays to 123 Sulzer HiFi Trays for improved C2 Splitter performance – higher capacity and stringent product purity.

Revamp Objective: • Increase capacity by 25% • Ethylene Purity : 99.96 wt%

Revamp Solution: Shell HiFi Plus Trays with • MMVG Fixed Valves • HiFi Downcomer Boxes • Long Weir Length > 23m During the Performance Test Run when the column was artificially loaded up for the highest throughput, steady operation was observed with a useful capacity around 95%, and a measured ethylene purity of 99.98%. A tray efficiency of 79% was achieved.

Case Study - New Xylene Rerun Column with Shell HiFiTM Plus Trays

A new Xylene Rerun Column, of ID 8.3m, was designed with 117 Shell HiFi Plus Trays. The design included 1 lattice beam for every 2 trays.

Process Requirements: • C9+ impurity in Distillate: <300 ppmwt • O-Xylene Recovery in Distillate: >99.0 wt%

Design Test Run

Ethylene Purity 99.96% 99.98%

Tray Efficiency 80% 79%

Full Assembly during Trial Layout at Workshop

Design Actual Operation

Feed 125% 100%

Reflux / Feed Ratio [mass] 1.61 1.84

Min. Recovery 99.0% 99.5%

Tray Efficiency 73% 74%

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Sulzer Design: Shell HiFi Plus Trays with • MVG Fixed Valves • 10 HiFi Downcomer Boxes • Long Weir Length > 60m

Although actual production was less than maximum loads, the reflux ratio was higher than design due to higher amount of impurities in feed. The Shell HiFi Plus Trays performed well, providing higher capacity while meeting the process requirements.

This column was compared with a similar column in client's plant, equipped with competitor's multi-downcomer trays, and proved to be better in terms of relative energy consumption and product recovery.

FRI Validation Key Areas of Application

• Refinery: Main Fractionators' PA and Stripping Sections• Olefins: Deethanizers, Depropanizers, Debutanizers, Deisobutanizers, SuperFractionators: C2 and C3 Splitters• Aromatics: Xylene Splitters, Xylene Rerun, Raffinate Columns• Gas Sweetening: Absorbers, Regenerators

Shell HiFi Trays, with tray spacings of 305mm and 610mm, have been tested at FRI, in the iso-butane/n-butane system at 11, 21 and 28 bar. As compared to 1-pass round valve trays with truncated downcomers, Shell HiFi Trays of same tray spacing, exhibit up to 40% higher capacity.

Shell Ultra-System Limit High Performance Trays

Shell ConSepTM TraysThe Shell ConSep trays are one of the highest capacity fractionation trays available on the market, offering up to 80% additional capacity over conventional trays without any major impact on separation efficiency.

They utilize the principle of de-entrainment by centrifugal force to overcome the gravitational limitation of jet flooding, and the system limit of the vessel.

Every set of ConSep tray consists of a primary tray (with chordal or HiFi downcomer layout) and a secondary tray with Swirl tubes.

FRI Validation

Shell ConSep Trays have been tested at FRI, in the iso-butane/n-butane system at 11bar. At least 50% higher capacity was observed over some other high performance trays, with a separation efficiency as high as 90% and capacity substantially exceeding the system limit of the column.

Key Areas of Application

• Refinery: Main Fractionators• Olefins: Deethanizers, Depropanizers, Debutanizers, Superfractionators C2 and C3 Splitters

Debutanizer Refinery 8

Depropanizer Refinery 5

Main Fractionator Refinery 2

Naphtha Splitter Refinery 1

Diesel HDT Stripper Refinery 2

H2S Stripper Refinery 1

C2 Splitter Olefins 1

PO Drying Column Chemicals 1

C6 Dryer Chemicals 1

Service No. of Columns

Case Study - Revamp of FCC Debutanizer to Shell HiFiTM Plus and ConSepTM Trays

A debutanizer was revamped from 2-pass chordal downcomer trays to high performance Shell Trays. Improved feed quality, increased throughput and conversion at FCC unit led to increased feed rate and more LPG content to the Debutanizer.

Revamp Objective: • Increase capacity by 15% • C5 content in Top Stream < 0.6 vol% • RVP of bottom LCN < 85 kPa

Revamp Solution: • 15 HiFi Plus Trays in Rectifying Section • 15 ConSep Trays in Stripping Section The column proven capacity after the revamp increased by 21%, exceeding the objective by 6%, with lower C5 content in the top (0.3 vol %versus 0.6 vol%) and lower RVP in LCN (77 kPa vs 85 kPa).Overall tray efficiency achieved was more than 86%, well above the tray efficiency of the first generation high performance trays used before revamp which was 69%.

Case Study - Debottlenecking of HGO Pumparound with Shell ConSepTM Trays

Shell ultra high capacity ConSep Trays were applied in the capacity constrained HGO Pump-around section of a Crude Distillation Unit in a refinery. This was the first application of ConSep Trays in a CDU. The post revamp test run established the realization of the expected performance.Revamp Objective: • Increase capacity by 53% • Maintain product specifications for Naphtha, Kero, LGO and HGOMain Modifications: • 3 Shell ConSep Trays in HGO PA section • 7 Shell HiFi Trays in stripping section • 1.3m Sulzer MelapakPlusTM 252.Y in wash section • 16 Shell CSTM trays in other sections

Industry

Experience List of Shell ConSep Trays:

Shell HiFiTM Sieve Trays with ConSepTM decks

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As of March 2014

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Mechanical Features

Non-Welded Tray Support SystemIn several revamp projects aimed to increase the separation stages of an existing column, the number of actual trays had to increase (e.g. 3-for-2, 4-for-3, or 5-for-4).

To accomplish this, a mechanical design is required to avoid impact on the schedule of the plant's turn-around, and minimize cost as well.

Sulzer has developed a mechanical solution enabling installation of the trays by reusing the existing tower attachments, without any direct welding to the tower wall, thus avoiding any post-welding heat treatment and/or hydraulic testing of the vessel. This technique consistently reduce the turnaround time by using this technique.

The following devices show in the illustration below are used:

• Expansion rings • Expansion joints • Vertical struts • Downcomer adaptors • Solid or lattice beams

The system can be also used for other purposes: modify the geometry of existing downcomers, modify the number of passes; change the tray orientation; replace packing beds with trays.

Trays for Heavy Duty ServicesIn some applications, particularly those subjected to operating upsets leading to panel dislodgment, the trays must withstand higher than normal mechanical loadings, i.e. 7000 N / m2 (1 psi) or even 14000 N / m2 (2 psi).

In such cases, special features may be employed in the mechanical design:

• Through-bolting panel connection • Shear clips • Downcomer spreaders • Explosion doors

Expansion ring Vertical strut

Existing support ring

Lattice beam

Expansion joint

2 psi uplift BDHTM tray equipped with through-bolting assembly, shear clips and explosion doors

Services

Computer-Aided Engineering (CAE): 3D Models Upfront engineering and design play a crucial role in cost optimization. Sulzer has integrated all major mass transfer products into an in-house design tool, creating a global standard.

Customers profit directly from the use of our internal CAE tool. Layout drawings supplied in the course of the engineering phase will show a 3D sketch of the equipment being designed, for an easy and fast checking by the customer.

Natural Frequency Analysis for Tray Vibration PhenomenaIn some critical applications and under specific operating conditions, vibration phenomena may be induced to the trays. Based on plant feed-back data and in-house know-how, Sulzer has developed a design tool to check for the following two main parameters:

• Natural frequency of the tray panels, as a function of the geometry, the supports, and the material of construction.

• Vibration factor, as a function of the flow rates and physical properties of the streams being processed.

Finite Elements Method (FEM) and Computational Fluid Dynamics (CFD)Sulzer also employs other advanced design tools, for example verification of mechanical integrity and functionality using finite element and CFD analysis.

Turn Around and Tower Field ServicesSulzer’s global manufacturing capabilities ensure fast delivery of any tray hardware and replacement tray parts, regardless of original supplier. These can be manufactured from existing drawings or damaged parts and supplied on site quickly to meet your turnaround schedules. Replacement hardware can be supplied on consignment in lockers or trailers for convenience.

Natural frequency analysis of a full tray

Lip-SlotTM Panel ConnectionThe Lip-Slot is an enhanced type of tray panel connection which allows for:

• safe and easy installation • up to 30% less installation time • less maintenance costs as it does not use any bolted connection • same mechanical reliability as conventional connections

The Lip-Slot is combined with universal clamps for the fixation around the tray periphery.

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www.sulzer.comPlease check for your local contact

Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with headquarters in Winterthur, Switzerland, is active in the field of process engineering and employs some 4500 persons worldwide.

Sulzer Chemtech is represented in all important industrial countries andsets standards in the field of mass transfer and static mixing with its advanced and economical solutions.

The activity program comprises:

• Process components such as fractionation trays, structured and random packings, liquid and gas distributors, gas-liquid separators, and internals for separation columns

• Engineering services for separation and reaction technology such as conceptual process design, feasibilities studies, plant optimizations including process validation in the test center

• Recovery of virtually any solvents used by the pharmaceutical and chemical industry, or difficult separations requiring the combination of special technologies, such as thin film/short-path evaporation, distillation under high vacuum, liquid-liquid extraction, membrane technology or crystallization.

• Complete separation process plants, in particular modular plants (skids)

• Advanced polymerization technology for the production of PLA and EPS

• Tower field services performing tray and packing installation, tower maintenance, welding, and plant turnaround projects

• Mixing and reaction technology with static mixers

• Cartridge-based metering, mixing and dispensing systems, and disposable mixers for reactive multi-component material

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Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to be construed as implying any warranty or guarantee of performance. Sulzer Chemtech waives any liability and indemnity for effects resulting from its application.22.88.06.40 - X.14 - 10